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International Journal of Engineering Science Invention (IJESI)
ISSN (Online): 2319 – 6734, ISSN (Print): 2319 – 6726
www.ijesi.org ||Volume 7 Issue 7 Ver II || July 2018 || PP 25-38
www.ijesi.org 25 | Page
Study on Mechanical and Tribological Properties of Glass Fiber
Reinforcedepoxy Composites with Sic & Flyash as Fillers
Ramesh Ganugapenta1, S Madhusudan
2,K Balaji
3 P Prathyusha
4
1M.Tech(Ph.D), Asst. Professor, Dept.of ME, Vemu Institute of Technology,Chittoor.
2Pg Scholar, Dept.of ME, Vemu Institute of Technology, Chittoor.AP.
3Asst. Professor, Dept.of ME, Vemu Institute of Technology, Chittoor.AP.
4Asst. Professor, Dept.of ME, Bomma Institute of Technology,Khammam.TS.
Corresponding auther : Ramesh Ganugapenta
Abstract : Glass fiber reinforced polymer composites are one of the most widely used composite materials due
to its light weight and high impact resistance used for aerospace, marine and other industrial applications.
Glass fiber used in industrial applications to make polymer matrix composite is having chemical inertness in
nature. In this work, a method is proposed to add fly ash and Silicon carbide (Sic) content to polymer matrix for
enhancing the overall strength and improve tribological properties of the composite. In this method polymer
matrix composites are fabricated by using hand lay-up technique in different weight percentages of fly ash and
Sic (5%, 10%, 15%, and 20%).The mechanical properties such as tensile, compression, impact and hardness
properties are studied as per ASTM standards. Experimental investigation on Tribological properties of Flyash
and silicon carbide reinforced Glass fiber epoxy composites with different weight (0%,5%,10%) percentages
using pin-on-disc machine and analysis of tribological characterstics in ANOVA are done in this work.
Keywords - Glass fiber, hand lay-up technique ,Silicon carbide, pin-on-disc machine.
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Date of Submission: 20-06-2018 Date of acceptance: 06-07-2018
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I. INTRODUCTION A composite material is made by combining two or more materials are together to create a superior,
unique material properties, minimizes their weakness and chemically distinct phases. A composite material is
heterogeneous at a microscopic scale but statistically homogeneous at macroscopic scale. The composite
materials have significantly different properties. The composites materials can be naturally or artificially made
materials. There are many researches for new materials which will satisfy the specific requirements for various
applications like aerospace, marine, industrial, structural, electrical, house-hold, etc.
II. TYPES OF COMPOSITE MATERIALS These three types of matrix produce three common types of composites
Polymer matrix composites (PMCs): Polymer matrix composites are comprised of a variety of short or
continuous fibers bound together by an organic polymer matrix. The advantage of PMCs is their light weight
coupled with high stiffness and strength along the direction of the reinforcement. This combination is the basis
of their usefulness in aircraft, automobiles, and other moving structures.
Metal-matrix composites (MMCs): In metal matrix composites use silicon carbide fibers embedded in a
matrix made from an alloy of aluminum and magnesium, but other matrix materials such as titanium, copper,
and irons are increasingly being used. Typical applications of MMCs include bicycles, golf clubs, and missile
guidance systems.
Ceramic-matrix composites (CMCs): The ceramic matrix makes them particularly suitable for use in
lightweight, high-temperature components, such as parts for airplane jet engines .Ceramic matrix composites
(CMC) are produced from ceramic fibers embedded in a ceramic matrix. Various ceramic materials, oxide or
non-oxide, are used for the fibers and the matrix.
III. APPLICATIONS OF GLASS FIBER Storage tanks, house hold, piping system, traffic lights, Helicopter rotor blades, surf boards, rowing shells
Introduction of Epoxy Resin
Epoxy resins are polymeric or semi-polymeric materials, and as such rarely exist as pure substances,
since variable chain length results from the polymerization reaction used to produce them. High purity grades
can be produced for certain applications, e.g. using a distillation purification process. One downside of high
purity liquid grades is their tendency to form crystalline solids due to their highly regular structure, which
Study On Mechanical And Tribological Properties Of Glass Fiber Reinforcedepoxy Composites With .
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require melting to enable processing. The applications for epoxy-based materials are extensive and include
coatings, adhesives and composite materials such as those using carbon fiber and fiber glass reinforcements
(although polyester, vinyl ester, and other thermosetting resins are also used for glass-reinforced plastic).
Hardener
Hardener is high viscous liquid material, mixed with resin in suitable proportion during the process of
preparation of composites which helps in the solidification of the wet, smooth composite. It is used to harden the
smooth composite hence it is called as hardener.
Catalyst
Catalysis is the increase in the rate of a chemical reaction due to the participation of an additional
substance called a catalyst. With a catalyst, reactions occur faster and require less activation energy.
Fly ash
Coal-burning power plants that consume pulverized solid fuels produce large amounts of coal ash.
These are the finely divided mineral residue resulting from the combustion of ground or powdered coal in
electric power generating plant. The coal ash consists of inorganic, incombustible matter present in the coal that
has been fused during combustion into a glassy, amorphous structure
IV. FABRICATION PROCESSES Wet/Hand Lay-Up:
The fibers are first put in place in the mould. The fibers can be in the form of woven, knitted, stitched
or bonded fabrics. Then the resin is impregnated. The impregnation of resin is done by using rollers, brushes or
a nip-roller type impregnator. The impregnation helps in forcing the resin inside the fabric. The laminates
fabricated by this process are then cured under standard atmospheric conditions. The materials that can be used
have, in general, no restrictions. One can use combination of resins like epoxy, polyester, vinyl ester, phenolic
and any fiber material. Fig 1.1 shows the simple hand layup technique.
Advantages of Hand Lay up:
The process results in low cost tooling with the use of room-temperature cure resins.
The process is simple to use.
Any combination of fibers and matrix materials are used.
Higher fiber contents and longer fiber as compared to other processes.
Disadvantages:
Since the process is worked by hands, there are safety and hazard considerations.
The resin needs to be less viscous so that it can be easily worked by hands.
The quality of the final product is highly skill dependent of the labour.
Uniform distribution of resin inside the fabric is not possible. It leads to voids in the laminates.
Possibility of diluting the contents.
Fig 1.1 HandLay Up Technique
V. APPLICATIONS OF COMPOSITE MATERIALS: Aerospace: Aircraft, spacecraft, satellites, space telescopes, space shuttle, space station, missiles, and booster’s
rockets, helicopters (due to high specific strength and stiffness) fatigue life, dimensional stability.
Missile: Rocket motor cases, Nozzles, aerodynamic fairings etc.
Launch vehicle: Inter stage structure, High temperature nozzles, and control surfaces etc.
Composite railway carriers: Bodies of railway bogeys, seats, doors, gear case, pantographs etc.
Sports equipments: Tennis rockets, golf clubs, base-ball bats, helmets etc.
Automotive: Drive shafts, fan blades, clutch plates, gaskets, engine parts etc.
Industrial: conveyer belts, hoses, tear and puncture resistant fabrics, ropes, cables etc.
Medical: Wheel chairs, crutches, Hip joints, surgical equipments etc.
VI. LITERATURE REVIEW Basavarajappa et al [1] have done their project using the optimization technique Taguchi and perform
to acquire data in a controlled way. An orthogonal array and analysis of variance (ANOVA) was employed to
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investigate the influence of process parameters on the wear in composite materials. Based on Taguchi approach,
the experimentation provides an orderly way to collect, analyzes, and interpret data. Incorporation of the silicon
carbide particles in the polymer matrix as a secondary Reinforcement increases the wear resistance of composite
material. Applied load is the wear factor that has the highest physical as well as statistical influence on the wear
of composite material.
B.Suresha et al [2] carried out experimentation to study the influence of two inorganic fillers of SiC
particles and graphite on wear of the glass fabric reinforced epoxy composites. They reported that the increase
of load and sliding velocity results higher wear loss. The coefficients of frictional values are increasing with
increase of load and sliding velocities. By investigation, the Graphite filled glass fiber composite has lower
coefficient of friction. Silicon carbide and Graphite filled composites exhibits maximum wear resistance.
Inclusion of Graphite and silicon carbide filler particles in Glass fiber composite reduces friction and gives
better wear resistance properties.
V. Manikandan1 et al [3] Conducted experimentation to study the influence of fly ash fillers on
mechanical and tribological properties of woven jute fiber reinforced polymer hybrid composite. Composites
were prepared using hand layup method with weight percentage of fly ash as filler material. Inclusion of Filler
percentage increases hardness and wear resistance properties but decreases the tensile strength of composite
material decreases.
VII. EXPERIMENTAL DETAILS Fabrication of Composites
Hand lay-up technique is the simplest and oldest open molding method of composite fabrication
process. In this work, Silicon carbide, fly ash powder of different weight percentages (0%,5%,10%,15%,20%)
as shown in Fig 3.1 are mixed with epoxy-hardener mixture and fiber reinforcements and filler materials of
epoxy mixture are placed manually against the mold surface as shown in Fig3.2.The thickness is controlled by
layers placed against the mould. After the preparation of specimens, the work pieces are cured for 24 to 48 hrs
so that work pieces will get hard as shown in Fig 3.3. After this, the specimens were cut according to ASTM
standards using cutting machine as shown in Fig3.4 and finished the composite material with Emory paper as
shown in Fig 3.5. The designations of work pieces are shown in Table 3.1.
Fig 1.2 Mixture of matrix material with varies wt% of fillers Fig 1.3 Fabrication by hand lay-up method
Table 1.1 Designation of work pieces Material code Glass Fiber(wt%) Matrix(wt%) SiC Filler
(wt%)
FlyAsh filler
(wt%)
Bare 50 50 0 0
S1 50 45 2.5 2.5
S2 50 40 5 5
S3 50 35 7.5 7.5
S4 50 30 10 10
a b c
Fig 1.4 a. Solidified composite material after curing 48 hours at room temperature
Fig 1.5 b. Cutting of composite material by switch board cutting machine
Fig 1.6 c. Cutting of composite material as per ASTM standards
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Fig 1.7 Specimens of S1 composite material for pin-on-disc test
Fig 1.8 Specimens of S2 composite material for pin-on-disc test
VIII. TENSILE TEST Tensile test is conducted as per ASTM D638 IV standards specimen cut in to 33× 6 × 5. Tensile test is widely used to find the behavior of material when subjected to a slowly applied tensile load. It is
conducted on computerized universal testing machine (UTM).
As per ASTM standard Test specimen of composite material of uniform flat cross-section is gripped in the jaws
of machine at the both ends and a pull is exerted axially. The stress-strain curve obtained for composite material.
Table 1.2 Technical specifications for computerized version universal testing machine MODEL TUE-C-600
Measuring capacity (KN) 600
Measuring Range (KN) 0-600
Least count (KN) 0.06
Resolution of piston movement(mm) 0.1
Overall dimensions approx(mm) 2200 × 800 × 2400
Weight approx(kg) 3100
Distance between columns(mm) 600
Piston stroke(mm) 250
Power supply 3 phase 415v 50HZ AC
Total H.P 2.5
Pair of compression plate diameter(mm) 120
Tension test jaws for flat specimen thickness(mm) 0-30
Tension test jaws for Maximum width of flat specimen(mm) 70
IX. COMPRESSIVE TEST Compression test is conducted as per ASTM D3410 standards specimen cut in to 140 × 12.7 ×
3.Compressive test is conducted on computerized universal testing machine in a similar way as tensile test, but
the direction of loading is reversed. Component subjected to a compressive force does not deform uniformly. If
the material is plastic instead of brittle, it bulges at its mid-section. In this test stress rises rapidly near the end
of the test due to an increase in area of the specimen.
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Fig 1.9 Compression Test Rig
X. CALCULATIONS OF MECHANICAL PROPERTIES Calculation of Tensile modulus
Tensile Modulus (E) = Stress
Strain
Stress = Load at peak (KN )
Area of cross −section (mm2)
Stress for bare material = 8.52
6×5
=0.284 N/mm2.
Strain for bare material = Lf−Lo
Lo
= 37−33
33
=0.1212.
Tensile modulus for bare material (E) = stress
strain
E = 0.284
0.1212
E = 2343N/mm2
Tensile modulus for S1 material E = 2947.56 N/mm2
Tensile modulus for S2 material E = 3712.50 N/mm2
Tensile modulus for S3 material E = 3094.059 N/mm2
Tensile modulus for S4 material E = 2719.47 N/mm2
XI. EXPERIMENTAL PROCEDURE OF WEAR TEST Set wear track radius 35mm Unscrew to loosen sliding plate move it to positioning at 35mm by looking
at the graduated scale.
Procedures for wear display loosen LVDT lock screw to bring LVDT Plunger visually to mid
position.The wear reading display on controller should be as near to zero. Initialize wear display to zero pressing
zero push button on controller.Apply normal load place required weights on loading pan slowly without
shaking.Move loading arm away from Friction force load cell button and pressing frictional force zero
button.Setting disc speed and set time on controller.Note down the values of wear, Frictional Force, coefficient
of friction of varies wt% of composite materials and changing control parameters.
Table 1.3 Experimental results of bare material SPEED (RPM)
LOAD (KG)
TIME (MIN)
WEAR(MICRO METERS)
FRICTIONAL FORCE (N)
COEFFICIENT OF FRICTION
300 2 5 132 9.1 0.449
300 4 10 139 17.4 0.447
300 6 15 133 20.8 0.343
600 2 10 145 8.1 0.373
600 4 15 146 16 0.35
600 6 5 204 21.9 0.35
900 2 15 187 7.5 0.387
900 4 5 152 12.9 0.304
900 6 10 394 15.1 0.258
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The coefficient of friction between surfaces normally increases with increasing temperature and decreasing load.
In almost all cases, a lower coefficient of friction will lead to a lower wear rate.
Fig 1.10 Taguchi Analysis in Mini Tab
XII. RESULTS & DISCUSSIONS TENSILE TEST RESULTS
Tensile test Report for Bare Material
Fig 2.1 Generated Graph of Stress Vs Strain for Bare material
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Tensile test Report for S1 Material
Fig 2.2 Generated Graph of Stress Vs Strain for S1 material
Tensile test Report for S2 Material
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Fig 2.3 Generated Graph of Stress Vs Strain for S2 material
Tensile test Report for S3 Material
fig 2.4 Generated Graph of Stress Vs Strain for S3 material
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Tensile test Report for S4 Material
Fig 2.5 Generated Graph of Stress Vs Strain for S4 material
Figs 2.1-2.5 show the tensile test reports and computer generated graphs. It observes from the generate
graphs; S2 material has higher tensile strength then other glass fiber composite materials. Table 1.4 and Fig 1.6
below clearly show the variations of tensile strength of various composite materials.
Table 1.4 Tensile Test Comparison Results MATERIAL TENSILE STRENTH(N/mm2)
BARE 355
S1 449
S2 451.25
S3 375
S4 412
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Fig 2.6 Tensile strength comparison graphs of composite materials
COMPRESSION TEST RESULTS
Compression test Report for Bare Material
Fig 2.7 Generated Graph of Load Vs Elongation for Bare material
0
50
100
150
200
250
300
350
400
450
500
BARE S1 S2 S3 S4
TENSILE STRENTH(N/mm2)
TENSILE STRENTH(N/mm2)
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Compression test Report for S1 Material
Fig 2.8 Generated Graph of Load Vs Elongation for S1 material
Table 1.5 Mechanical properties of composite materials Material Tensile
strength (N/mm2)
Tensile
modulus (N/mm2)
Compression
Strength (N/mm2)
Impact
Strength (J/mm2)
Hardness
(kgf/mm2)
Surface
Roughness (µm)
Bare 355 2343 480 0.1 6.629 1.08
S1 449 2947.56 1325.893 0.128 19.06 0.675
S2 451.25 3712.5 1556.143 0.1428 14.87 0.545
S3 375 3094.06 868.714 0.1714 13.56 0.37
S4 412 2719.47 1086.429 0.2 16.37 0.24
Table 1.5 shows the mechanical properties of various glass fiber reinforced composites. the mechanical
properties of various glass fiber reinforced composites. It observes from above graph bare material has higher
surface roughness, S1 material has higher hardness, S2 material has higher tensile strength and tensile modulus,
finally S4 material has higher impact strengths then other glass fiber composites.
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Wear test results
Fig 2.9 Wear rate and Friction Force Acquire for Experiment 1
Fig 2.10 Wear rate and Friction Force Acquire for Experiment 5
Fig 3.1 Tribological characteristics Vs Time Acquire for Experiment 5
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XIII. ANOVA ANALYSIS RESULTS Table 1.6 L9 (3× 𝟑) Orthogonal Array and analyzed Taguchi Design for Wear in Bare Material
SPEED(RPM)
LOAD(KG
) TIME(MIN)
WEAR(MICRO
METERS)
S/N
RATIO(db)
FITS_SN
1 RESI_SN1 %ERROR
300 2 5 132 -42.4115 -41.1464 -1.2651 2.982917
300 4 10 139 -42.8603 -42.6348 -0.22553 0.526198
300 6 15 133 -42.477 -43.9677 1.49063 -3.50926
600 2 10 145 -43.2274 -44.718 1.49063 -3.44835
600 4 15 146 -43.2871 -42.022 -1.2651 2.92258
600 6 5 204 -46.1926 -45.9671 -0.22553 0.488238
900 2 15 187 -45.4368 -45.2113 -0.22553 0.49636
900 4 5 152 -43.6369 -45.1275 1.49063 -3.41599
900 6 10 394 -51.9099 -50.6448 -1.2651 2.437107
Table 1.7 Analysis of Variance for SN ratios
Source DoF
Sum of sqaures
ss MS F P Contribution
SPEED(RPM) 2 29.805 14.903 2.56 0.281 40.53448
LOAD(KG) 2 23.17 11.585 1.99 0.334 31.51095
TIME(MIN) 2 8.935 4.467 0.77 0.565 12.1515
Residual ERROR 2 11.62 5.81 15.80307
Total 8 73.53 100
Table 1.8 Response Table for Signal to Noise Ratios Smaller is better Level SPEED(RPM)_1 LOAD(KG)_1 TIME(MIN)_1
1 -42.58 -43.69 -44.08
2 -44.24 -43.26 -46
3 -46.99 -46.86 -43.73
Delta 4.41 3.6 2.27
Rank 1 2 3
Table 1.6 show L9 (3× 3) Orthogonal Array and analyzed Taguchi Design for Wear in Bare Material.
It can be observed from the results obtained from Table 1.7 that speed was the most significant parameter
having the highest statistical influence (40.53%) on the dry sliding wear of composites followed by load
(31.51%) and time (12.15%).When the P-value for this model was less than 0.05, then the parameter or
interaction can be considered as statistically significant. This is desirable as it demonstrates that the parameter or
interaction in the model has a significant effect on the response. From an analysis of the results obtained it is
observed that the interaction effect of load & speed is significant influencing wear rate of bare composites.
Table 1.8 give rankings to influencing parameters based on these speed is most influencing on wear of bare
material.
XIV. CONCLUSION In this project, Fabrication of various glass fiber reinforced composite materials. The mechanical
properties are observed by experimentation on different weight percentages of fly ash and Sic (5%, 10%, and
15% 20%). In mechanical experimental work, results obtained is bare material has higher surface roughness, S1
material has higher hardness, S2 material has higher tensile strength and tensile modulus, finally S4 material has
higher impact strengths then other glass fiber composites. Experimental investigation on Tribological properties
of Flyash and silicon carbide reinforced Glass fiber epoxy composites with different weight(0%,2.5%,5%)
percentages using pin-on-disc machine and analysis of tribological characterstics in ANOVA are done in this
work. The results concluded that
In base material wear was influenced by factors speed followed by load and time.
In base material frictional force (FF) was influenced by factors Load followed by speed and time.
In base material coefficient of friction (CF) was influenced by factors speed followed by load and time.
In S1 material wear was influenced by factors time followed by load and speed.
In S1 material frictional force (FF) was influenced by factors Load followed by time and speed.
In S1 material coefficient of friction (CF) was influenced by factors load followed by speed and time.
In S2 material wear was influenced by factors load followed by speed and time.
In S2 material frictional force (FF) was influenced by factors Load followed by speed and time.
In S2 material coefficient of friction (CF) was influenced by factors speed followed by load and time.
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XV. FUTURE SCOPE Conduct vibration tests on these glass fiber reinforced composite materials
Conduct erosion tests on these glass fiber reinforced composite materials and the obtained results are predict by
Artificial neural network(ANN) software.
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Ramesh Ganugapenta "Study on Mechanical and Tribological Properties of Glass Fiber
Reinforcedepoxy Composites with Sic & Flyash As Fillers "International Journal of
Engineering Science Invention (IJESI), vol. 07, no. 07, 2018, pp 25-38